Ugh, Broken Cam Cover Bolt

[miggytosh]

Agreed, the finish on the exposed interior of the cam cover appears to be holding on. The seals have not been removed in the photo. Does this indicate a plan to re-install the cover without further removing / disturbing anything?

The seals for the spark plugs and the two plastic plugs (remnants from 928 roots as I understand it) came off without the original finish coming off and I have fresh replacements. Feeling very lucky overall. I showed a picture of the cam/valve train and the underside of the cover to the service manager of Porsche SF and he thought both looked to be in very good condition considering the age and miles (110K).

[dr bob]

The seals for the spark plugs and the two plastic plugs (remnants from 928 roots as I understand it) came off without the original finish coming off and I have fresh replacements.

Over the years there have some interesting discussions among 928 owners about the plug well seals. Specifically about them dropping or hanging off the tubes as the cover is placed, then getting cut or pinched when the cover is tightened. I've made it a habit to use a small inspection mirror down the well while the cover is just resting on the plug bosses, and looking 'around' the bottom of the tube to make sure the seal is still in place before pushing the cover down the final time and dropping the bolts in. I think I mentioned that I like to use a film of Hylomar on those seals, so they can move around as needed to seal without distortion as you secure the cover.

I've become a fan of Hylomar sealant, learned from some industrial maintenance techs for delicate oil and hydraulic components in turbine controls and other related things. It stays soft in service, vs. other sealants that harden or at least 'firm up' like silicones and most 'non-hardening' sealants. A very thin film is all you need or want on those seals, or in the cover groove for the gasket. I used it on the head side of the gasket too, but still added a smear of the recommended silicone at the corners. I know many have their favorite products for these things, Hylomar just happens to be mine.

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The plastic plugs block off holes that were eventually used on GTS series 928's in the final years. The larger motors seemed to have more blowby issues in their final years, so had some additional venting there via 90º nipples and hoses to the 'vapor recovery system' such as it was-- Just connections indirectly back to the intake. I don't know if the duty on the four cylinder cars would benefit from extra venting there, but if so there are factory 928 bits that would make that a bit easier.

'Performance' 928 builds vent those ports to a more effective aftermarket AOS over the oil filler neck. Some serious builds go further, and install oil scavenging tubes there, plumbed a scavenging pump. That unloads the oil return passages for better vapor flow.

[CEW]

Lots of great info here! I am preparing to replace the cam cover gasket on my S2 in the near future.

A couple questions:
Other than a cam cover gasket kit and both tensioner pads (and maybe a new set of bolts), what other parts would I want to have available for this job?

Where do you recommend I get these parts? Pelican, 944online, Rockauto, dealership, ???

Also, Dr. Bob, which Hylomar sealant do you use?

Thanks in advance for the advice and recommendations.

[dr bob]

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Also, Dr. Bob, which Hylomar sealant do you use?

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Easiest is Permatex "high performance blue" in a small tube, the thumb size. Usually at your favorite parts store, or a click-and-deliver service. I bought a bigger tube and most of it is in my garage chems fridge, waiting for the next duty. I use it for certain other things where it's perfect, but still in just tiny tiny doses.